Coil unit



.im i1, 1944.

E. E. FRANZ COIL UNIT -Filed April 5, 1941 2 Sheets-Sheet 1 F l G. 2

/NVENTOR 5.5; FRA NZ Jim U10-elm ATTORNEY Jan. 11, 1944. E; E. FRANZ2,339,067

COIL UNIT Filed April 5, 1941 2 Sheets-Sheet 2 /NVENTOR E.E. FPA/VZ.ATTORNEY Patented Jan. 11, 1944 COIL UNIT Erwin E. Franz, Cranford, N.J., assgnor to Western Electric Company, Incorporated, New York, N. Y.,a corporation of New York Application April 5, 1941, Serial No. 387,017

6 Claims.

This invention relates to coil units, and more particularly toelectrical coil units used in the communications arts.

An object of the invention is to provide a simple, eliicient and highlypractical electrical coil unit.

With this and other objects in view, one embodiment of the inventioncomprises an electrical coil unit having companion head members formedfor the winding of a coil thereon and with grooves in one of the membersfor the securing of a selected number of like terminals in place, theterminals having shoulders over which leads from the coil may extend andadjacent diagonally extending portions about which the leads may bewound.

Another embodiment of the invention comprises U-shaped heads similar instructure to the ends of one of the heads of the other embodiment andformed also to receive a selected number of terminals, reversibleelements being illustrated in this embodiment with oppositely disposedserrations for use in removing either separate leads from the coil orleads in the form of loops and maintaining the course of winding of thecoil.

Other objects and advantages will be apparent from the followingdetailed description when considered in view of the accompanyingdrawings, wherein Fig. 1 is an end elevational view of an electricalcoil unit, portions thereof being broken away to illustrate oneembodiment of the invention;

Fig. 2 is a side elevational Vview of the unit shown in Fig. 1, portionsthereof being broken away;

Fig. 3 is a top plan view of the structure shown in Fig. 2, portionsthereof being broken away;

Fig. ly is an end elevational view of another embodiment of theinvention, portions thereof being broken away;

Fig. 5 is a fragmentary side elevational view of the structure shown inFig. 4;

Fig. 6 is an enlarged fragmentary detailed view taken substantiallyalong the line 6 6 of Fig. 5;

Fig, 7 is a fragmentary detailed view-similar to the showing in Fig. 4,illustrating one of the lead guiding elements;

Fig. 8 is a perspective view of the head members, of the rst embodiment,spaced from each other to illustrate the structure thereof, and Fig. 9is a perspective view of one of the heads of the other embodiment.`

Referring now to the drawings, attention is first directed to Figs. 1 to3 inclusive and Fig. 8, which illustrate companion heads I0 and whichare substantially U-shaped in general contour as well as in crosssection and formed, at their inner portions, to completely surround acentral core member I2.

The adjacent ends of the heads I0 and II are spaced from each other, asat I3, excepting where the portions I4 of the heads adjacent the coreproject upwardly to close the spaces. These spaces I3 at each side ofthe heads and at each end thereof make possible the projection of leads,hereinafter described, therethrough. The heads I0 and II have flange orwall portions I6 and Il, respectively, joining in completing theU-shaped cross sectional contour of the heads and forming alignedcompartments in which coils I8 and I9 'may be wound. In the presentembodiment the central flanges or walls are illustrated dividing theheads into separate compartments for the different coils I8 and I9, butif desired the central wall may be eliminated if but a single coil isdesired to be wound on the heads. One important feature is pointed outat this point, this being the fact that the winding of the coil or coilsupon the heads serves as a means to secure the heads together and uponthe central core member I2, eliminating the necessity of other securingmeans to accomplish this purpose.

The head I0 has U-shaped portions 2D integral with the outer walls |6thereof andV projecting outwardly as illustrated in Fig. 1. A series ofvertical slots 2| is formed at spaced positions in the portions 20,these slots having cooperating recesses 22 and 23 communicatingtherewith :at their upper and lower extremities and extending at rightangles with respect thereto, as shown in Fig. 2. The lower surfaces ofthe portions 20 adjacent the openings I3 are serrated, as at 25, formingamultiplicity of retaining grooves for leads 26 of the coils I 8 and/orI9. i

Like terminals 28 of the strip type illustrated taken from a supply arereceivable in selected slots 2| and have integral lugs 3D receivable inthe recesses 22 adjacent the selected slots, while the lower ends of theterminals have integral tabs 3| which may be bent laterally into theadjacent recesses 23 to thus secure the terminals in the slots. Theportions of the terminals disposed in the slots 2| have diagonallyextending notches 33 extending partially into the slots 2| and formingportions 34 with diagonal surfaces E about which the leads 26 may bewound. Integral with the portions 34 and at the lower extremitiesthereof, outwardly projecting portions @t form shoulders 3l upon whichthe leads may rest when Wound about the portions 34. The structure thusformed may be positioned to submerge the portions 34 and 36 of theterminals in a molten solder bath to solder the leads to the terminals,this requiring, of course, separate soldering steps for the terminalsupon each side of the structure.

The core structure may then be completed by securing, in any desiredmanner such as by the aid of non-magnetic channel members 38 and rivets39, outer core members 4i) to the central core member l2. In completingthe core structure mounting studs 4I may be included for use insubsequently mounting the coil unit to. a suitable support such as aframe (not shown). The assembly may now be lowered into a contained; 42and an insulating covering 43 positioned to close the open end of thecontainer 42, the covering being held in place by integral tabs 44 ofthe covering bent inwardly as illustrated in Figs. 1 to 3 inclusive.

With this embodiment of the invention a desired number of terminals,depending upon the number of leads to be taken from the coils I8, i9,are mounted in selected slots 2| in the head it. The leads 26, some ofwhich may be taken near the beginning of lthe winding of the coils andothers at the ends of the coils whilestill others may be takenintermediate the ends and the beginning of the coils, are projectedoutwardly upon either side of the heads or at either end thereofthroughy the openings I3, where they are freed of their insulation. Whenthis has been accomplished each lead is passed through a notch,Y in theadjacent serrated surface 25, which is in alignment with the point-,where the lead leaves the coil, after which the lead may be extendedoutwardly and upwardly toward its terminal. The notch orserrated portionin the serrated suriace servesl to hold the lead in a definite positionwith respect to the point Where it leaves its coil, to eliminatepossible disturbance in the winding` of the coil, The lead is then drawnover the shoulder 31 of its terminal and wrapped about the portion 34.In the wrapping of the lead about the portion 34, the lead enters asubstantially V-shaped groove formed by the surface 35 of the terminaland the adjacent wall of the head the: vertex of which is smaller thanthe diameter of the lead, making it possible for the lead to be wedgedtherein. In reality, the wedging` effect is enhanced by four edges, two`edges of the surface 35 and the edges of the adjacent slot 2l. As soonas the lead is wrapped about the portion 3 4Y and wedged in place, acontinued pull on the free endv of the lead will cause breakage thereofadjacent the last edge of the surface 35, this edge serving toL shearthe freeend of the lead from that wound about the portion 34 of theterminal.

The embodiment illustrated in Figs. Il to 7 inclusive and Fig. 9` hasfeatures in common to those shown in Figs.r l to 3 inclusive, in thatthe terminals are identical in structure, the heads diliering ,only inthe, fact that they do not, surround a central core member. Forexamplesthe heads 5a are U-.shaped in general contour and identical. tothe U-shaped portions. 2l). of the head li); Therefore, should thecentral and outer walls I6, which are disposed between the portions 29,be removed, the remaining structure, that is, the

portions 2l! would be identical to the heads 50. The heads 53, only oneof which is shown, are disposed at opposite sides of a central coremember 5l about which a coil 53 is wound, the coil serving the samefunction as the coils I8 and i9 in the first embodiment, of securing theheads til in place, eliminating the need of additional securing means tomount the heads on the central core member. In this embodiment terminals515, identical in structure to the terminals 28, and having projectinglugs are selectively disposed in a plurality of slots 53 in the sidewalls of the heads Sii, so that the lugs 55 will rest in lateralrecesses 5l' while integral tabs 58 of the terminals at the lower endsthereof may be bent laterally into recesses The lower portions of theterminals iid have notches til extending diagonally into. the slots 5t,forming surfaces 6I on portions t2 which cooperate with the adjacentwalls of the heads in forming recesses to wedgingly receive leads $3 ofthe coil. The terminals also have portions Gil adjacent their lowerends, forming shoulders b5 upon which portions oi the leads, may rest inbeing wound upon the portions, 62 of the terminals. Attention is alsodirected to the serrated under surfaces 6.5 of the heads, formingnotches for receiving the leads 63.

An additional feature is added to this embodiment which may also beemployed with the embodiment illustrated in Figs. l to 3 inclusiveshould it be desirable to eliminate the central wall It oi the head lli.This feature includes elements (il of the contour illustrated in Fig. 7.These elements are formed of suitable material, for example, fromcellulose acetate sheets, and are notched at their ends, as at 68, tointerengage. the inner portions of the side Walls of the heads 5i?. 'Theother edges of the elements are serrated, as at B9, providing series ofnotches to receive leads in forming taps from the coil. The functions`of the elements lil are to hold the convolution-s of the coil againstdisturbance or displacement, particularly at the leads, and to insulatethe leads from each other and from the convolutioiisoi the coil. The useof these elements is of utmost importance in the removal oi leadsintermediate the ends of the coil to maintain the winding course of thecoil.

In viewing Fig. 7, let it be assumed that the coil 53 is only partiallywound and that it is desirable to remove a double lead in the form of aloop therefrom. At this point one of the elements 67' may be 'disposedin place over the convolutions of the coil thus formed including thelest convolution from which a lead 1U will extend. The wire of this lastconvolution which passes beneath the element El, as illustrated at l,may be bent into the adjacent notch of the adjacent serrated edge 39 tohold the convolutions, particularly the last one, in place while drawingthe lead, outwardly, through an aligned notch in the serrated surfaceE56 and upwardly toits respective terminal. In passing upwardly, thewire is extended over the shoulder 65 and around the portion t2. Inpassing or wrapping the lead wire around the portion 62, the lead may bedrawn downwardly into the V-shaped recess, where itwill be wedged inplace. Following lthis step, the lead Wire is then passed downwardlybeneath the adjacent wall of the head through another, but adjacent,notch in the serrated surface Gfi and upwardly to a position above theupper edge of the rst element 61. Another element El; may then bedisposed over the :first element and in a like manner held in placethrough its inner connection with the side walls ci the head,positioning the last mentioned portion of the lead wire between the twoelements. At this time the lead wire may be disposed in a desired notchof the upper Surface of the last mentioned element, so that it may beadjacent 'the last convolution of the coil and in order that the windingof the coil may be continued with the convolutions lying in paralleladjacent positions.

If desired, two separate leads may be formed by the aid of the elements61 instead of a single loop, the separate leads being directed toseparate terminals and secured thereto in the manner previouslydescribed and illustrated in Fig. 6.

lli/'hen the coil has been completed and the desired leads secured totheir respective terminals, the structure thus far completed may bedisposed relative to a solder bath to submerge the portions 62 and 64 ofthe terminals, with the leads secured thereto, in the bath to solder theleads to the terminals. The coil structure may then be completed bysecuring outer core members 13 to the central core member 5i by anysuitable means such as angle members 14, formed of suitable non-magneticmaterial, and rivets 15. The upper rivet 'i5 may also secure mountingstuds 'I6 in place for the mounting of the coil unit shown in thisembodiment to a suitable support such as a frame. The coil unit thus farcompleted may be disposed in a casing 1T, the open end of which may beclosed by a plate i8, formed of suitable insulating material and havingapertures through which the terminals 54 and the studs 16 project,

secured in place through the aid of tabs 'I9 integral with the casingand bent inwardly as in Fig. 3.

The embodiments of the invention herein disclosed are merelyillustrative and may be modied and departed from in many ways withoutdeparting from the spirit and scope of the invention as pointed out inand limited solely by the appended claims.

What is claimed is:

l. An electrical coil unit comprising a hollow head, a coil having alead and wound with convolutions thereof disposed in the head, aterminal carried by the head and formed for the securing of the leadthereto, and an element formed for interengagement with the head andhaving recesses disposed adjacent the convolutions and employed toselectively receive the lead at its juncture with any desired one of theadjacent convolutions to hold the convolutions against displacementduring the securing of the lea'd to the terminal.

2. An electrical coil unit comprising a hollow head including sidemembers, a coil having leads and wound about the head, between the sidemembers thereof, and about a core to secure the head in place about thecore, terminals carried by the side members, and a reversible elementinterengageable with the head between the side members thereof andhaving recesses disposed adjacent the convolutions and adapted toselectively receive the lead at its juncture with any desired one of theadjacent convolutions to guide the leads to their respective terminalson either member and hold the convolutions against displacement.

3. In an electrical unit having a coil with leads and wound on a core, ahead having a portion interposed between the coil and the core and aside member, having a slot therein, disposed free of the coil and core,and a terminal rigidly mounted in the said slot and having a notchtherein extending into the slot to receive a lead from the coil, asurface of the terminal at the notch and the adjacent edges of the slotcooperating to wedgingly hold the lead against displacement.

4. In an electrical unit having a coil with leads and wound on a core, ahead having a portion interposed between the coil and the core and aside member, having a slot therein, disposed free of the coil and core,and a terminal disposed in the said slot and having a notch thereinextending diagonally into the slot to receive a lead of the coil andprovide a surface cooperating with adjacent edges of the slot towedgingly hold the lead against displacement.

5. In an electrical unit having a coil with leads and wound on a core, ahead having a portion interposed between the coil and the core and aside member, having a slot therein, disposed free of the coil and core,a terminal disposed in the said slot and having a notch thereinextending diagonally into the slot to receive a lead of the coil andprovide a surface cooperating with adjacent edges of the slot towedgingly hold the lead against displacement, and means to rigidly mountthe terminal inthe slot.

6. In an electrical unit having a coil with leads and wound on a core, ahead having companion portions surrounding the core, formed for thewinding of the coil thereon and having a side member on one of theportions with a slot therein, and a terminal disposed in the said slotand having a notch therein extending diagonally into the slot to receivea lead of the coil and provide a surface cooperating with adjacent edgesof the slot to wedgingly hold the lead against displacement.

ERWIN E. FRANZ.

